Flexible package and method of forming a cuff

ABSTRACT

A package having a foldable top region is provided. The package generally includes panel portions that at least partially define an interior cavity therebetween and accessible through an access opening. The top portion can provide a cuff member or cuff region that can be folded and unfolded to facilitate use of the package as a bowl or other cuffed container for material contents. The package can be adapted to hold its shape as a bowl or cuffed container. A reclosure member can be provided to facilitate re-sealing of the package. A folding strip, edge contours and stiffening members can also be provided.

PRIORITY

This Application claims priority to and the benefit of U.S. Provisional Application No. 61/772,369, filed Mar. 4, 2013, which is hereby incorporated herein by reference in its entirety.

FIELD

The present invention relates generally to flexible packaging and, more particularly, to packages having a cuff, and methods for forming a cuff or cuffed region, or using packages as a bowl or cup.

BACKGROUND

Flexible packages used for items like food, liquid and other material content are meant to store, transport and serve as the consumption container. Namely, it is often desirable to have a package adapted for the end user to consume the contents directly from the package, rather than transferring the contents to a bowl, plate, or other container or device. Such conventional designs are often cumbersome and difficult to use. For instance, typical stand-up packages are not capable of use as a bowl or to drink out of because they are not generally stable, are not able to hold their shape, and present sharp points or edges that can cause injury.

As a result, there is a need for a flexible package that substantially solves the above-referenced problems with conventional package designs, use, configurations, and manufacturing methods.

SUMMARY

The present invention solves many of the problems facing flexible packages and the packaging industry. Embodiments of the present invention are directed to a package generally capable of forming a cuff, or to convert the package into a bowl or cup. The package can include a front, back and bottom panel portion to define an interior accessible through an access opening. The bottom panel can be configured to provide a stand-up pouch configuration for the package, with the bottom panel defining a base measurably wider than the height of the package to create a stable stand-up configuration in certain embodiments. The package can further include one or more side panel portions, gusseted or non-gusseted. The interior is capable of storing and dispensing product or other objects, including solids and liquids.

In various embodiments, the package can be provided with a reclosure member or zipper. A folding strip can also be provided to the package panels to facilitate folding. Contours can be provided to the panels and side seals to facilitate folding as well. More than one fold line can be defined. The sides or other panels can be gusseted. One or more stiffener members can also be provided to the side panels. The cuff forming portion can also be configured to define a trough around the perimeter of the open top of the package. Outward extending seams on the package can be eliminated by overlapping adjacent panels and bonding, gluing or taping the overlapped panels together.

The package can include a top region proximate the access opening, the top region having a cuff member, such as an access device for one-time or re-closeable use. The access device can permit selective access into the internal cavity of the package through the access opening. The top region can be foldable about a fold area proximate the cuff member such that a cuff is presented. It is envisioned that various creases, or added structures such as rigid or semi-rigid members, can be provided along or proximate the fold area to facilitate folding along the fold area. The above summary of the invention is not intended to describe each illustrated embodiment or every implementation of the invention. The figures in the detailed description that follow more particularly exemplify these embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may be more completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the accompanying drawings, in which:

FIG. 1 is a front view of a package with a cuff member or cuff region in accordance with an embodiment of the present invention.

FIG. 2 is a cut side view of the package of FIG. 1.

FIG. 3 is a top view of the package of FIG. 2, containing package contents.

FIG. 4 is a side view of the package of FIG. 2, showing an end user folding the top region.

FIG. 5 is a side view of the package of FIG. 1, with the top region folded over or downward to create a cuff.

FIG. 6 is a top view of the package according to FIG. 5.

FIG. 7 is a cut side view of a package with a cuff member or cuff region in accordance with an embodiment of the present invention.

FIG. 8 is a cut side view of a package with a cuff member or cuff region in accordance with an embodiment of the present invention.

FIG. 9 is a front view of a package with a cuff member or cuff region in accordance with an embodiment of the present invention.

FIG. 10 is a front view of a package with a cuff member or cuff region in accordance with an embodiment of the present invention.

FIG. 11 is a front view of a package with a cuff member or cuff region in accordance with an embodiment of the present invention.

FIG. 12 is a front view of a package with a cuff member or cuff region in accordance with an embodiment of the present invention.

FIG. 13 is a perspective view of a side-gusseted fin seal package with a cuff member or cuff region in accordance with an embodiment of the present invention.

FIG. 14 is the same view as FIG. 13, but with the cuffed portion folded to form a cuff.

FIG. 15 is a perspective view of a side-gusseted quad-seal package with a cuff member or cuff region in accordance with an embodiment of the present invention.

FIG. 16 is the same view as FIG. 15, but with the cuffed portion folded to form a cuff.

FIG. 17 is a front view of a package with a cuff member or cuff region in accordance with an embodiment of the present invention.

FIG. 18 is a front view of a package with a cuff member or cuff region in accordance with an embodiment of the present invention.

FIG. 19 is a front view of a package with a cuff member or cuff region in accordance with an embodiment of the present invention.

FIG. 20 is a front view of a package with a cuff member or cuff region in accordance with an embodiment of the present invention.

FIG. 21 is a front view of a package with a cuff member or cuff region in accordance with an embodiment of the present invention.

FIG. 22 is a front view of a package with a cuff member or cuff region in accordance with an embodiment of the present invention.

FIG. 23 is a top view of a package with a cuff member or cuff region in accordance with an embodiment of the present invention.

FIG. 24 is a side sectional view of a package with a cuff member or cuff region in accordance with an embodiment of the present invention taken along lines A-A of FIG. 25.

FIG. 25 is a front view of the package of FIG. 24.

FIG. 26 is another side view of the package of FIG. 24.

FIG. 27 is a side view of the package of FIG. 24, showing the top region folded over or downward to create a cuff.

FIG. 28 is a top partial sectional view and a detail view thereof taken along line B-B of FIG. 26.

FIG. 29 is a side sectional view of a package in accordance with an embodiment of the present invention.

FIGS. 30A-30D are side detail views of a folding strip portion or feature of a package in accordance with an embodiment of the present invention.

FIG. 31 is a side view and detail view of a package in accordance with embodiments of the present invention.

FIG. 32 is a front view of a package in accordance with an embodiment of the present invention.

FIG. 33 is a front view of a package in accordance with an embodiment of the present invention.

While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the invention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims. For illustrative purposes, hatching or shading in the figures is provided to demonstrate sealed portions and/or integrated devices for the package.

DETAILED DESCRIPTION

In the following descriptions, the present invention will be explained with reference to various example embodiments; nevertheless, these embodiments are not intended to limit the present invention to any specific example, environment, application, or particular implementation described herein. Therefore, descriptions of these example embodiments are only provided for purpose of illustration rather than to limit the present invention.

A purpose of the present invention is to form a package, such as a flexible package, to have a top region or portion capable of folding over to form a cuff. Such a cuff configuration facilitates using the package as a bowl or other like container for accessing or dispensing material contents. The various embodiments and teachings provided herein can also be employed with a semi-rigid package. References to “top,” “bottom,” “front,” “back,” and the like are for illustrative purposes only and are not meant to limit the scope of the disclosed invention.

Referring to FIGS. 1-3, a flexible package 100 and components and configurations in accordance with certain embodiments of the present invention are shown. The package 100 can include a front panel portion 102, a back panel portion 104, a cuff region 124, and a top region or portion 120. In various embodiments, the top region or portion 120 of the package 100 can include a space or gap defined between the cuff region 124 and a top edge 121 of the package 100. The distance of the gap or space can vary greatly depending on the particular formation and usage needs for the subject package 100.

In addition, the package 100 can include one or more side panel seals 106, 108 and a bottom panel portion 122. The bottom panel portion 122 can be gusseted to provide a stable base for the package 100, but other non-gusseted embodiments are envisioned as well. One or both sides of the package can also include side panel portions (not shown), gusseted or non-gusseted.

In the depicted embodiments, the joining and/or shaping of the above-referenced panels define the package 100 with an interior or internal cavity 125, generally having an adjustable internal volume capacity for holding material contents 110.

The panel portions are often referred to as “webs” or films. Each panel can be formed from an individual web or, alternatively, each of the panels can be portions of a larger single web, wherein the large web is folded, cut and/or shaped to define the individual and distinctly defined panel portions and, ultimately, the shape and size of the package 100. Regardless of the formation techniques or the use of separate web panels, a distinct or distinguishable panel portion is defined for each panel. Further, one or more of the panel portions can be gusseted. In an upright or stand-up flexible package 100 of one embodiment, the base or bottom panel portion 122 can be defined by a base width distance “B” measurably greater than the height distance “H” of the front and back panels 102, 104, as shown in FIG. 1. This configuration provides a stable base region to adapt the package 100 for use as a bowl or other standing container for material contents 110. Other dimensional and proportional configurations for the package and its respective panels are envisioned as well. For instance, the base or bottom panel portion 122 distance “B” can be greater than the depth “D” of the bottom panel, or the bottom panel expanded depth “D” from the front panel to the back panel, to provide a stable stand-up package configuration.

The various package panel portions are generally constructed of flexible sheet material such as polyethylene, polyester, metal foil, polypropylene, or polyethylenes or polypropylenes laminated with other materials such as nylon, polyester, and like films. To provide for increased barrier properties, embodiments can use composite layers of said materials and material of the like. Generally, in such composite embodiments, a material having preferred sealing characteristics can be joined, bonded or laminated to a material having a different preferred characteristic (e.g., beneficial oxygen barrier properties). Regardless, single sheets, composites/laminates, and a myriad of other materials and techniques known to one skilled in the art may be implemented based on particular usage and manufacturing needs without deviating from the spirit and scope of the present invention.

The package 100 and its portions can be formed to provide a stand-up pouch, pre-made pouch, bag-top, one formed and filled on a “form-fill-seal” machine, and other known package designs and configurations. Other known package designs and packaging techniques and features can be adapted to incorporate or form the configuration of the present invention as well.

In certain embodiments, a locking member, access device or reclosure member 128 can be provided to or defined in one or both of the front and back panel portions 102 and 104. In the particular example shown in FIG. 2, the reclosure member 128 comprises a first zipper portion 128′ provided to the front panel 102 and a second zipper portion 128″ provided to the back panel portion 104. The respective reclosure portions can be brought together to seal/re-seal the package a plurality of times. Thus, the contents are less likely to spill, less likely to be contaminated and freshness time will be extended.

Various fixed zippers, slider zippers, adhesives/tapes, snap or screw cap devices, snap fasteners, hook and latch fastening, spouts, fitments, and other like techniques and devices known to one skilled in the art can be employed for use as the access device or reclosure member 128. In addition, the employment of various techniques, devices or machines for attaching access opening devices to flexible packaging sheets or webs are envisioned for use with the present invention. Alternative embodiments of the access device 128 can be single or minimal use access devices, folding flaps, spouts, holes, and the like. Additionally, a peel seal can be included, with or without an access device or zipper interlock feature. Further, the cuff member 124 or access device 128 can be disposed along any portion of the package 100, e.g., sides, bottom, and the like, without deviating from the scope of the present invention. The package can also be formed without a reclosure device 128.

A thinned portion, weakened portion or score line 130 can also be defined in the cuff member or region 124. This weakened portion/score line 130 can be defined in the reclosure member or in the panel portion. This feature 130 helps to define a fold line (132 in FIG. 1) about which the cuffed portion 124 can be folded by the user. The feature 130 also defines a region proximate the top of the package 100 to facilitate folding of the top portion 120 to create the cuff 126 as shown in FIG. 5 and hold the round shape of a bowl or cup.

In other embodiments, the package 100 may instead include a rigid member, semi-rigid member, film member, or other structures or configurations to define a region proximate the top of the package to facilitate folding of the top as described above. Also, in various embodiments, no cuff member or access device at all is required to facilitate formation of the cuff 126. Instead, the general proportions, materials and overall design and configuration of the package can alone, or in combination, enable folding of the top, or other regions of the package proximate an opening, to create the cuff 126 feature and to hold the shape of a bowl or cup.

In additional embodiments, the top portion 120 can further include a slit, laser score, tear notch or other known means of facilitating the opening of the sealed top portion of the package to allow access to the reclosure device or member 128, and/or the internal cavity 125.

In use, the package 100 can first be provided in an uncuffed configuration, such shown in FIGS. 1-3. The access device 128 can induce or provide a level of shape memory to define a cuff portion 124 that will form the cuff. The shape memory feature can also cause the cuff portion 124 to form a cuff 126 when the top portion is removed and the package contents accessed.

To provide a cuff according to certain embodiments, the user generally grabs the opened top portion of the package 100, as shown in FIG. 4, and folds it downwardly over the outside of the package to form a cuff structure 126 such as that shown in FIG. 5. This down-fold, or folding, creates a cuff 126 at the top (or the bottom or sides) of the package 100 that results in positioning the access device 128 outwardly of the package 100 as shown in FIG. 5. As such, the top of the package 10 is generally free of sharp or pointy edges.

The shape memory of the cuff region 124 or of the closure device 128 in certain embodiments can tend to form outwardly curved portions when the cuff is formed that urge the opposing panels 102 and 104 away from each other so as to open the package and reveal the contents of the package. Thus, the rounded bowl or cup shape can be maintained by the package as shown in FIG. 6.

The user can alternatively fold the top inward at least once to form the cuff 126 inside the package 100.

The package 100 can also be provided with multiple cuff portions 124 so that different size cuffs can be formed as the user consumes the package contents.

The described and depicted package configurations provide a cup-shaped or bowl-shaped package with a wide opening such that the user can selectively shape the cup or bowl, with the cup or bowl generally retaining the desired shape during use because of the additional structure and configuration of the cuff 126. With such configurations, the package 100 can be used as a container vehicle for material contents, solids or liquids. For instance, people or animals can eat or drink directly from the package 100, reducing the chance of injury because of the rounded top edges. In addition, the cup or bowl can be used by a human to hold, transport or consume food or liquids.

After using the package 100, the end user can fold or un-cuff the cuff portion 124 to return the package 100 to its original configuration. The user can then also seal the [package 100 using the closure member 128, if present.

Referring to FIGS. 7 and 31, an alternative embodiment is shown wherein the front and back panel portions 102 and 104 are provided with a folding strip 134 on the inside of each panel portion. The folding strip comprises an upper and a lower strengthened portion 136 with a weakened/thinned portion or score line 138 defined therebetween. The top portion of the package will thus be pre-disposed to fold along the score line 138 when forming the cuff. The folding strip 134 can be either on the inside surface of the package as shown in FIG. 7, or it can be on the outside surface of the package as shown in FIG. 29.

Referring to FIG. 8, another alternative embodiment is shown wherein the front and back panel portions 102 and 104 are provided with both a reclosure device 128 and a separate folding strip 134. This configuration provides for flexibility in configuring the package for various cuff sizes while using common reclosure devices and folding strips.

Referring to FIGS. 30A-30D, several alternative folding strip or feature embodiments are shown. In FIG. 30A, the score line 138 has an arcuate cross-sectional shape. In FIG. 30B, the score line 138 comprises a V-shaped cross-sectional shape. In FIG. 30C, the score line 138 is defined between two raised ribs 139. In FIG. 30D, no strengthened portions 136 are provided. Instead, a score line 138 is defined directly in the film forming the package surface.

Referring to FIGS. 9-10, an alternative embodiment is shown wherein the side seals 106 and 108 are provided with a contour region 140 defined therein. The contour region 140 facilitates folding of the top portion to form the cuff. The contour feature can be combined with the folding strip 134 to form a score line 138 (as shown in FIG. 9) to additionally enhance the foldability described herein. The contour can be only formed in one or both of the side seals. Any edges intersecting with gussets can be contoured as well.

The contour 140 can be formed via a corresponding contour shape on the seal bar. Some, or all, of the contoured portion 140 can then be removed or notched in a subsequent punching process. Use of this two-step process instead of punching only helps to maintain the integrity of the seal. Merely punching can thin the seal adjacent the punched region, which can compromise the seal.

The contour 140 can be formed in any shape, including V-shaped (e.g., FIG. 33), polygonal, and arcuate. The contour can also be relatively large (e.g., FIG. 32), or larger, or smaller than shown in the figures. Multiple contour regions can be formed as well as will be discussed herein below. The contour can be either inwardly-extending or outwardly extending. Also, any stiffener member or reclosure member can be contoured in cross-section in order to facilitate foldability of cuff region.

FIG. 11 shows a further alternative wherein the reclosure device 128 is provided to one or both of the front and back panels in combination with the contour portion 140 as previously discussed. A folding strip is not present, but could be optionally provided.

FIG. 12 shows an alternative shape of the contour in the sides compared to the previously illustrated embodiments. The contour 140 here is of a smaller radius. It should be understood that the invention includes other shapes and sizes, such as V-shaped, that provide the equivalent function of the contours/notches disclosed herein. More than one contour 140 can also be provided, such as that shown in FIG. 19, so that the user can continue to fold down the package sides as the package contents are consumed.

FIG. 13 shows a fin-seal package according to various embodiments of the invention that further includes side gussets 142. FIG. 14 illustrates the package of FIG. 13 after a cuff 126 is formed. A vertically-oriented seam 144 extends the height of the package.

FIG. 15 shows another alternative package embodiment having a quad-seal, again including side gussets 142. Here, the front 102 and back 104 panels do not include a seam 144 as is shown in FIG. 13. FIG. 16 shows the package of FIG. 15 with the cuff 126 formed. Note that the cuff here shows the optional formation of a far more oval-shaped opening compared to that of FIG. 14.

Referring to FIG. 17, a further alternative embodiment of the package invention is shown. A plurality of stiffener members 146 are disposed on each of the front and back panels. Each stiffener member comprises an elongated strip disposed horizontally across the panel to which it is disposed. The strip could also be vertically oriented. One stiffener 146 can be provided, or a plurality of horizontally-spaced (or vertically-spaced) apart stiffeners 146 can be provided. The stiffeners provide additional structural support to the package so it can be grasped by the user's hand like a cup without the package collapsing in the user's hand due to the force of grasping the cup in this manner.

Each member 146 also defines an additional fold line and cuff region to permit the user to fold the package as the contents is consumed. The members can also be provided with weakened sections or scope lines.

Another feature illustrated in FIG. 17 is that the edges of the font/back panels have an inwardly-defined inset portion 148. The inset 148 is defined by the convergence of a first and a second inwardly-angled sidewall portions 150 and 152, respectively. Note that the first portion 150 is much shorter and steeper than the second portion 152. A folding strip 134 can be provided at the point of convergence of the first and second portions. This arrangement facilitates the easy and predictable folding of the top portion 120 of the package to form a cuff 126 as shown in FIG. 18.

After the cuff 126 is formed, the package of FIG. 18 generally resembles a cup. Thus it is ideally suited for drinkable liquids, such as beverages or soup, but it can be used with any type of contents according to the invention. A reclosure device is not shown, but can be provided to a portion of the top region 120 in order to make the package re-sealable.

Referring now to FIGS. 20-23, a further embodiment is shown. This embodiment provides for the formation of a trough 154 around the perimeter of the package opening. This is particularly useful for putting dip, salsa, etc. in the trough 154 when the contents 125 of the package is chips or vegetables.

The package 100 according to this embodiment includes an extended height cuff-forming portion 124 as shown in FIG. 20. The trough 154 is formed by folding the entire cuff-forming portion 124 downwards to form an oversized cuff 126, as shown in FIG. 21. Next, the cuff 126 is folded upward at about its approximate mid-height to form a secondary cuff 127 as shown in FIG. 22. A top view of this configuration is shown in FIG. 23, wherein it can be clearly seen that a trough 154 is formed. The trough will be generally v-shaped in cross section and have the maximum depth of the upwardly folded cuff portion described previously. Thus, the dip, salsa, etc. can be maintained in the trough 154 separate from the package contents 125, but in easy-access proximity for the user.

Referring now to FIGS. 24-28, additional aspects of the invention will be discussed. The package as shown includes a folding strip 134 provided to each of the front 102 and back 104 panels. Side seals 106 and 108 are again formed at the interface of the front and back panels (or gusset if present). A notch 141 is defined in the side seals. But here, the side seals are formed flat against the package walls as shown in FIG. 26. This makes for a smoother dispensing configuration as shown in FIG. 27 because there is no flange of material extending outwardly from the package. This also facilitates foldability and provides further rigidity to the package, especially if used as a cup or like structure.

The seals are formed flat as can be seen in the cross section B-B view and detail view thereof in FIG. 28. The front or back panel slightly overlaps the other and adhesive, tape or similar substance 156 is disposed between the overlapped panel portions. Instead of adhesives or other substance, the overlapped panel portions could also be melted together to form a continuous wall.

Various figures and descriptions disclose features and accessories. However, it must be noted that these features are merely illustrative in nature and may be placed in varying locations and under varying configurations, and still be consistent with the present invention.

In addition, the shape and configuration for the panel portions are also merely illustrative and can be altered without deviating from the spirit and scope of the present invention. Any of the panel portions, or selected regions thereof, can include various aesthetic and functional graphics, such as logos, instructions, advertising, bar codes, and the like. These graphics can run transverse, parallel, or even in a diagonal orientation to the longitudinal panel edges discussed herein.

The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof, and it is, therefore, desired that the present embodiment be considered in all respects as illustrative and not restrictive. Similarly, the above-described methods and techniques for forming the present invention are illustrative processes and are not intended to limit the methods of manufacturing/forming the present invention to those specifically defined herein. A myriad of various unspecified steps and procedures can be performed to create or form the inventive package 10. 

What is claimed is:
 1. A method of providing a flexible package as a bowl-like or cup-like container, comprising: providing a flexible package having at least first and second panels defining an inner cavity, the first and second panels each having respective interior and exterior surfaces, with a first cuff region defined along a portion of the interior surface of the first panel proximate a first edge portion; providing a folding strip to the cuff region adjacent the respective inner surfaces, the folding strip comprising an upper and a lower strengthened portion with a region of weakness defined therebetween; and manipulating the flexible package proximate the region of weakness to form a generally rounded access opening by folding a portion of the cuff region extending above the region of weakness until the portion of the cuff region extending above the region of weakness is inverted adjacent the exterior surfaces of the first and second panels.
 2. The method of claim 1, further comprising providing a closure member to at least one of the first and second panels.
 3. The method of claim 2, wherein the closure member and the folding member are separate from one another.
 4. The method of claim 1, further comprising defining a contour region in the first edge portion.
 5. The method of claim 5, further comprising notching the contour region.
 6. The method of claim 1, further comprising defining a plurality of contour regions in the first edge portion.
 7. The method of claim 1, further comprising providing a plurality of laterally-oriented stiffening members to at least one of the first and second panels
 8. The method of claim 1, further comprising folding a second portion of the cuff region in an upward direction until the second portion of the cuff region forms a trough around a top perimeter of the package.
 9. The method of claim 1, further comprising overlapping a portion of the front and back panels and disposing adhesive therebetween.
 10. The method of claim 1, wherein providing the flexible package further includes providing a bottom panel such that at least the first, second and bottom panels define the inner cavity and the flexible package is configured as a stand-up package.
 11. The method of claim 1, wherein the first and second panels are each defined by a width dimension and a height dimension, with the width dimensions being greater than the respective height dimensions. 